SAMPLE QUALITY ASSURANCE PLAN

30.5m Welded Open Web Girder (25T Loading-2008) as per RDSO’s Drg. No. RDSO/B-11678

Name of project ………………………………………………………………………………..... ………………………………………

…………………………………………………………………………………………………………………………………………………

Manufactured by ……………………………………………………………………………...... …………………………………………

Workshop Address………………………………………………………………………………………………………
SN Component/ Characteristic Frequency Reference Fabricators Inspection details Type of Acceptance Remarks
Operations Check & type of Document Quality Record criteria
check Control Inspecting Extent of
Agency inspection
1 2 3 4 5 6 7 8 9 10 11

1.0 Raw Material

1.1 Steel Plates, Identification As per Mill Challan, Verification …………. 100% Fabricator’s Plates: IS
Structural Section and correlation T.C. and Mill T.C. of reference Railway record 2062-2006,
with Mill Test tests document Gr. E 250 B0,
Certificate required by 12mm &
from Supplier RDSO from above thick.
e.g., SAIL, Govt./NABL Plates are
TISCO, IISCO approved fully killed &
etc. lab normalized or
control
cooled.
Sections IS
2062-2006,
Gr. E 250
B0/A
Physical Visual - Complete ………… 100% Fabricator’s IS 2062- -
condition i.e., visual Railway Record 2006
Pitting, rusting, inspection
straightness,
rolling defect,
etc.

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Fabricating Agency Railway Representative
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Mechanical Lab Test at - Lab Test ………… - - IS 2062- Raw matl.

Test as per IS appvd. Report Railway 2006 Gr. E Clearance
2062-2006 Laboratory 250 B fully shall be by
UTS, YS, % killed & Zonal
El, Bend test, normalized Railway
or control
cooled
Charpy test -Do- - -Do- ………… Heat/Cast - - -
0
at 0 C for Railway no. section
plates of thks. wise as per
12mm and IS 2062-
above 2006
Chemical -Do- - -Do- ………… -Do- - Table 1,
Analysis as Railway along with
per IS 2062- Note No. 2
2006 of IS 2062-
2006, Gr. E
250 B
Ultrasonic By ASN - Lab Test ……… 100% - IS 4225 or
test for 12mm Level II Report Railway ASTM SA
& above thi. operator 435/435M
Plates, as per
IS 4225 or
ASTM-SA
435/435M
Dimensions Measurement Challan Measurement ……… 100% Fabricator’s
of Dimension Railway Record &
Zonal
Railway
Records
1.2 Rivets, Bolts & a) Dimensions Visual/ Challan Verification of ………… As per - For Rivet IS
Nuts Measurement Reference Railway requirement 1148 For
Document Bolt: IS
1367(Part ii)
& property
classes as
per relevant
Drg.
b) As per Lab test at Manufacturer’s -Do- -Do- -Do- -Do -Do
specn. Govt. appvd. Test
Mechanical Lab Certificate
& Chemical

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Fabricating Agency Railway Representative
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1.3 Paints Verification of Visual Challan., Vefification of …………... Each Batch Manufacturer’s IS 102, Paints to be
Manufacturer’s Manufacturer’s Reference Railway Test Contract procured
Test Test Document Certificate agreement from
Certificate, Certificate vendors
Inspection approved by
Certificate, RDSO
Challan
Tests as per Lab test at Challan., Verification of …………. Random Lab. Test IS 102 -Do-
Specification Govt. Appvd. Manufacturer’s Reference Railway Report Contract
Lab Test Document agreement
Certificate
1.4 Welding As per Any test as Challan., Verification of …………. As per Fabricator’s - Consumables
Consumables specification required Manufacturer’s Reference Railway requirement Record should be of
and as Test Document RDSO appvd.
approved by Certificate Brand
RDSO
2.0 Manufacturing
Process
2.1 Lay out of Dimension Measurement Approved Measurement RDSO 100% Iinspection Relevant Clearance
Components with Drawing of Dimension Report of IS/IRS by RDSO
& Joints calibrated Inspection Codes &
steel tape & Official Approved
a) Normal gauges Drawings
b) Jigs & Dimension, Measurement Approved Measurement RDSO 100% Record of Jigs IRS B1- Clearance
Templates Intersection with Drawing of Dimension & fixtures as 2001 by RDSO
lines, pitch, calibrated per proforma
gauge, dia. Of steel tape & issued by
Holes & No. of gauges RDSO
holes
c) Cutting, Dimension, Visual/ Inspection Visula& ……… 100% Inspection IRS B1-
Straightening, Freedom from Measurement Report of Measurement Railway Report of 2001, IS
Edge defect Inspection of dimension Inspection 1852-85
preparation Official & Official &
Fabricator’s Fabricator’s
Record Record
3.0 Welding:

a) WPSS Review of Verification IRS B1-2001 Verification of RDSO 100% Fabricator’s IRS B1- Only RDSO
WPSS IS 9595-96 Reference Record 2001 IS certified
WBC-2001 Document 9595-96 welders to
WBC- be engaged
2001 in the job.

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1 2 3 4 5 6 7 8 9 10 11

b) WPQR Witnessing of Visual, DT & As per code Verification of RDSO 100% WPQR Sheet IS 7310(I)-
established NDT at requirement Reference to be 74
WPSS approved lab Document recorded in
Witnessing of presence of
Welder RDSO Rep.
Qualification
test
c) Preheating Measurement Visual with As per approved Verification of …………. Random Inspection IRS B1-
of thermal WPSS Reference Railway Report of 2001
Temperature Chalk Document Inspection
Official &
Fabricator’s
Record
d) Baking of To have Visual Check As per Verification of ………… 100% Inspection IRS B1-
Electrode, Flux moisture free of Electrodes Manufacture’s Reference Railway Report of 2001
Electrode & & beating recommendations Document Inspection
Flux Officials &
Fabricator’s
Record
e) Selection of Reference to Visual As per approved Verification of ……….. 100% Inspection As per list
correct WPSS, IRS WPSS Reference Railway Report of of vendors
Electrodes & Class, etc. Document inspection approved
Flux official & by RDSO
Fabricator’s
Record
f) Current Measurement Visual with As per approved Verification of ………… Random Inspection IRS B1-
Condition of Amp. & Ammeter & WPSS Reference Railway Report of 2001
Voltage Voltmeter Document Inspection
Official &
Fabricator’s
Record
g) Sequence of To control Visual As per approved Verification of ………. Random Inspection IRS B1-
Welding distortion WPSS Reference Railway Report of 2001
Document Inspection
Official &
Fabricator’s
Record
h) Provision of To avoid Visual As per IRS B1- Verification of ………. 100% Inspection
Run-on & Run crater defects 2001 Reference Railway Report of
off Plates Document Inspection
Official &
Fabricator’s
Record

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Fabricating Agency Railway Representative
1 2 3 4 5 6 7 8 9 10 11
4.0 Inspection of a) For Fillet Visual, Approved Drg. & Visual RDSO 100% Fabricator’s Relevant Clearance
Welding Welds: Visual, Gauge & WPSS Inspection & Record IS/IRS by RDSO
D.P.Test Fillet Macro Verification of Code,
Size, Etching. dimension by Approved
Penetration, gauges Drg. &
Leg Length, WBC-2001
Throat
thickness, etc.
b) For butt
Welds RT/UT
tests, as
applicable
5.0 Trial a) Camber on Visual & Approved. Drg. Complete RDSO One Inspection IRS B1- Clearance
Assembly Jack Dimensional dimensional complete Report of 2001 by RDSO
b) Dead Load check of span Inspection
deflection Control Official &
Assembly Fabricator’s
c) Dimension Record
d) Fairness of
holes
e) Temporary
fasteners
f) Infringement
g) Butting of
compression
edges
6.0 Final Component Visual Stage clearance Verification of Day to day Girder Inspection IRS B1- Initial
Clearance completeness Dimensional Record Stage inspection fabrication Report of 2001 inspection
st
of 1 span & Structural clearance by Railways with Inspection by
after Record and final approved Official & Railways
dismantling & inspection Jigs-100% Fabricator’s and final
nd
2 span by RDSO Record Clearance
onwards by RDSO
7.0 Surface Surface Visual Approved Verification of ………… 100% by Fabricators IRS B1- Clearance
preparation by condition after checking with Fabrication stage Railway fabricator record 2001 shall be
Shot Blasting blasting reference to Drawing & IRS clearance & Random Appendix- given by
& Metalizing surface B1-2001 records by Railway VII Zonal
preparation IS: 6586 Railway
Surface finish Visual -Do- -Do- ………… -Do- -Do- IS: 5905
after checking Railway IS: 2590.
Metalizing
DFT checking Measurement -Do- -Do- ………… Minimum Measurement
Railway one reading Record
2
per M

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Fabricating Agency Railway Representative
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8.0 Cleaning & Surface Visual Approved Verification of ………… 100% by Fabricators IRS B1- Clearance
Painting condition checking . Fabrication stage Railway fabricator record 2001 shall be
before Drawing & IRS clearance & Random IS:104, given by
painting B1-2001 records by Railway IS:51, IS: Zonal
2339, IS: Railway
Surface finish Visual -Do- -Do- ………… -Do- -Do- 5666
after painting checking Railway
DFT checking Measurement -Do- -Do- ………… Minimum Measurement
Railway one Record
reading
2
per M
Note: 1. During fabrication, internal inspection to be done by Railways to ensure that only RDSO approved welders carry out welding as per approved
WPSS, work is as per dimensional tolerances and other quality aspects and should satisfy itself before sending Inspection call to RDSO for
Trial Assembly or components Inspection.
2. For ROB’s Inspection/Approval Agency for all stages will be concerned Railways.

Signature of Signature of Approval of RDSO

Fabricating Agency Railway Representative